Rusty Design: Revolutionising 3D, One Giant Print at a Time
The Rusty Design Team
Tom Murray, is part of the dynamic team at Rusty Design, a small but mighty manufacturing company based in Pontyclun, Wales that is redefining the potential of large-format 3D printing. Founded in 2018 by Morgan and his brother Bleddyn, Rusty Design has evolved from its early focus on prototyping for sports equipment into a multidisciplinary product development powerhouse.
At its core, Rusty Design specialises in designing and manufacturing custom, large-scale 3D printers, tools that allow them to produce everything from climbing holds to props, surfboards, and even sections of F1 cars. Their in-house developed software and hardware give them complete control over the creative and technical process, allowing innovation to flourish.
What sets Rusty Design apart is not just the scale of their work, but their commitment to sustainability. They actively explore biodegradable polymers and focus on reducing material usage. Their latest projects, backed by the Media Cymru Scale-Up Fund 2025, are centred around circular design, recovering materials at the end of a product’s life and using recycled materials from the start.
Their journey through the Media Cymru funding pipeline has been a key part of their growth. In 2023, they received seed funding, which enabled the team to carry out extensive interviews and collaborate with PDR on early-stage research. This was followed by development funding in 2024, allowing them to build functional prototypes. Now, in 2025, they are scaling up, expanding both their manufacturing capacity and material innovation efforts.
Tom joined as Lead Mechanical Engineer just before the company moved into a larger premises, marking a new chapter in their development. Alongside Tom, the team includes Project Manager and Engineer Danny Askew, experienced Prop Maker Kristian Mo, who brings over 15 years of expertise to the table, as well as Morgan and Bleddyn.
3D printed clay model
Rusty Design’s typical clients range from individuals with ideas looking to prototype, to funders and organisations in creative industries. Their projects have emerged from grassroots conversations, like their climbing hold venture, which began at a local freelancer meetup and has now progressed into prototype development with gym distributors.
Their portfolio of projects is as eclectic as it is impressive. From creating giant foosball players for TV (featured on Cwmni Da), to crafting a half-sized F1 car, they’ve tackled complex design challenges across various sectors. They were also part of a Smart Cymru EU-funded surfing project and are currently constructing their second custom-built 3D printer as part of the scale-up fund.
While their biggest challenge has been maintaining financial stability without backing from large investors, their determination and creative agility have seen them through. “It’s been about trusting the process and believing in our work,” Tom explains.
Looking ahead, Rusty Design is focused on material recovery, sustainable production, and expanding their reach across new industries. With their unique blend of technical skill, environmental ethos, and bold ideas, they’re carving out an exciting path for the future of advanced manufacturing.
